6thsemreport Government Engineering College, Patan.pdf

INDEX
Sr. No. TOPIC
1. ABSTRACT
2. INTRODUCTION
3. SPUR GEAR
⇒ OVERVIEW
⇒ 3D DESIGN OF SPUR GEAR (PROCEDURE)
4. BEVEL GEAR
⇒ OVERVIEW
⇒ 3D DESIGN OF BEVEL GEAR (PROCEDURE)
5. PLANETARY GEARBOX
⇒ OVERVIEW
⇒HISTORY OF PLANETARY GEARBOX
⇒ PLANETARY GEARBOX IN ROBOTICS
⇒ADVANTAGES OF PLANETARY GEARBOX
⇒LIMITATIONS OF PLANETARY GEARBOX
⇒APPLICATIONS OF PLANETARY GEARBOX
⇒ Analysis And Solutions For Planetary Gearbox Gear Damage
6. CANVASES
⇒ AEIOU CANVAS
⇒ MIND MAP CANVAS
⇒ IDEATION CANVAS
⇒ PRODUCT DEVELOPMENT CANVAS
⇒ LNM CANVAS
7. PROTOTYPE
⇒ DESIGN OF SPUR GEAR ALONG WITH SCREENSHOTS
⇒ DESIGN OF BEVEL GEAR ALONG WITH SCREENSHOTS
⇒ DESIGN OF PLANETARY GEARBOX ALONG WITH SCREENSHOTS
8. DETAILS ABOUT MODEL
9. FUTURE DEVELOPMENT OF PLANETARY GEARBOX
10. CONCLUSION
11. REFERENCES

ABSTRACT
Gears, the toothed workhorses of machines, are fundamental for transmitting power and
motion. This abstract explores the intricacies involved in designing these essential components.
This abstract emphasizes the importance of meticulous gear design in achieving efficient power
transmission, smooth operation, and extended lifespan for gears in diverse
mechanical applications.
Gearboxes, the workhorses of mechanical power transmission, rely on the precise design of
gears to function effectively. This abstract delves into the core principles of designing both
gears and gearboxes.
The abstract also acknowledges the importance of modern design tools like computer-aided
design (CAD) for gear profile optimization and gearbox performance analysis. Overall, this
abstract highlights the significance of meticulous gear and gearbox design in achieving
efficient and reliable power transmission across diverse engineering applications.
Here we will learn about design of various types of gears and Planetary Gearbox in Software
and theoretically.

INTRODUCTION
Gears are the essential building blocks behind countless machines, from the bicycles we ride
to the massive wind turbines generating electricity.
In essence, a gear is a toothed wheel that meshes with another toothed component. This
meshing allows gears to transmit rotational power and motion between shafts. By changing
the size (number of teeth) of the gears, we can control the speed and torque (turning force)
being transmitted.
Understanding gears and their design principles is fundamental to the world of mechanical
engineering. These fascinating components are the hidden heroes within countless devices,
making our machines run and our lives a little bit easier.
About Planetary Gearbox:
Planetary gearboxes, also known as epicyclic gearing, are a fascinating type of gear system
known for their unique design and distinct advantages.
Planetary gearboxes are ingenious mechanisms used in various applications, from wind
turbines and robots to car transmissions and even power tools. Their design is a captivating
blend of geometry and mechanical principles.

SPUR GEAR
OVERVIEW
Spur gears or straight-cut gears are the simplest type of gear. They consist of a cylinder or disk
with teeth projecting radially. Viewing the gear at 90 degrees from the shaft length (side on)
the tooth faces are straight and aligned parallel to the axis of rotation. Looking down the length
of the shaft, a tooth's cross section is usually not triangular. Instead of being straight (as in a
triangle) the sides of the cross section have a curved form (usually involute and less
commonly cycloidal) to achieve a constant drive ratio. Spur gears mesh together correctly only
if fitted to parallel shafts. No axial thrust is created by the tooth loads. Spur gears are excellent
at moderate speeds but tend to be noisy at high speeds.
Spur gears can be classified into two main categories: External and Internal. Gears with teeth
on the outside of the cylinder are known as "external gears". Gears with teeth on the internal
side of the cylinder are known as "internal gears". An external gear can mesh with an external
gear or an internal gear. When two external gears mesh together, they rotate in the opposite
directions. An internal gear can only mesh with an external gear and the gears rotate in the
same direction. Due to the close positioning of shafts, internal gear assemblies are more
compact than external gear assemblies.
3D DESIGN OF SPUR GEAR
For more control over our design and the ability to create more complex gears, we can use 3D
modeling software like Fusion 360, SolidWorks, or Inventor. These programs allow us to
create detailed models with precise dimensions and features.
Here's a general process for creating a spur gear in 3D modeling software:
• Define the gear parameters: This includes the number of teeth, pressure angle, module
(a unit that defines the size of the gear), and desired thickness.
• Create the base geometry: This involves creating circles for the pitch diameter, root
diameter, and tip diameter based on the chosen parameters.
• Model the teeth: We can use extrude features and circular patterns to create the involute
profile of the teeth.
• Add details: We can incorporate features like fillets at the base of the teeth, chamfers
on the edges, and a hole for the shaft.

BEVEL GEAR
OVERVIEW
Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of
the gears themselves are conically shaped. Bevel gears are most often mounted on shafts that
are 90 degrees apart, but can be designed to work at other angles as well. The pitch surface of
bevel gears is a cone, known as a pitch cone. Bevel gears change the axis of rotation of
rotational power delivery and are widely used in mechanical settings.
The bevel gear has many diverse applications such as locomotives, marine applications,
automobiles, printing presses, cooling towers, power plants, steel plants, railway track
inspection machines, etc.
3D DESIGN OF BEVEL GEAR
3D modeling software is the recommended approach for more control and complex bevel gear
designs. Popular options include Fusion 360, SolidWorks, and Inventor.
Here's a general workflow:
• Define Bevel Gear Parameters: Specify the number of teeth, pressure angle, shaft angles
(typically 90 degrees for right angle bevel gears), cone ratio (diameter ratio of large and
small ends), and desired thickness.
• Base Geometry: Similar to spur gears, you'll create circles for different diameters based
on the chosen parameters. However, these circles will be angled due to the bevel shape.
• Modeling the Teeth: This is the most intricate part. Software tools might have specific
features for bevel gears or you can create the teeth using extrude and revolve features.
The involute profile of the teeth needs to be formed along the angled surface. Tutorials
can be very helpful here.
• Adding Details: Include fillets at the tooth base, chamfers on edges, and holes for
shafts if needed.

PLANETARY GEARBOX
OVERVIEW
A planetary gear is a type of epicyclic gear system comprised of spur gears. In planetary gearing
(also known as epicyclic gearing), a centre gear, called a sun gear, serves as the input and driver
of the set. Three or more “driven” gears (referred to as planets) rotate around the sun gear
within a planetary gearbox. Finally, the planets engage with a ring gear from the inside, which
makes an internal spur gear design. Because the planet gears are evenly distributed around the
sun gear, planetary gear trains are known to be extremely rugged designs. Another benefit of a
planetary gearset is that it is easy to convert to a different ratio by simply changing out the
carrier and sun gears.
A planetary gearset uses spur gears that move opposite of each other within the same plane.
While spur gears are a more basic type of gear in terms of engineering since they do not utilize
specialty angles or cuts like bevel or herringbone gearing, they are complex in the tooth shape
design. Depending on the application, this tooth design will determine where the teeth make
contact, which then determines the available power, torque, and speed potential of the gears.
Planetary Gearboxes are a type of gearbox where the input and output both have the similar
center of rotation. This means that the centre of the input gear rotates about the center of the
output gear and the input and output shafts are allied.

HISTORY OF PLANETARY GEARBOX
The earliest example of a gear train dates to at least 2,000 B.C. when Chinese engineers built
a chariot that used a complex planetary mechanism made of wooden gears to let a dragon head
continuously point south when driven around. In Greece, a surprisingly advanced Antikythera
gearbox mechanism, incorporating at least 37 precisely crafted bronze gears, was built years
later, between 205–60 B.C.
Ever since then, engineers have used the extensive versatility of planetary gearboxes to
integrate scientific advances and materialize the dreams of their creative minds. In the 15th
century, Leonardo da Vinci dreamed of a helicopter he could not build, limited by substantial
technological barriers. Almost 500 years later, scientific advances allowed engineers to build
planetary gearboxes with sufficient torque density to enable Sikorsky and De la Cierva to build
helicopters that could lift their own weight. Today, advanced planetary gearboxes enable many
of the most impressive engineering masterpieces of our time, including helicopters, cars,
submarines, wind turbines, and industrial robots.
PLANETARY GEARBOX IN ROBOTICS
In robotics, planetary gearboxes were used in the joints of the first generations of industrial
robots, but limitations to minimize backlash resulted in their replacement with other gearbox
technologies. Today, cycloidal drive (CD) gearboxes are used in over 75 percent of the joints
of industrial robots especially the proximal joints while strain wave drives (SWDs) represent
around 20 percent typically in the more distal joints and planetary gearboxes are relegated only
to a fraction of the remaining 5–7 percent joints.
The arrival of modern collaborative robotic devices seems to be drastically altering this
paradigm. These devices have a marked need for lightweight actuation that has strongly
favoured the use of SWD gearboxes in their joints. Simultaneously, a trend can also be rapidly
identified toward using planetary gearboxes again in robotics. Cobot manufacturers like
Kinova and Automata incorporate self-developed planetary gearboxes in some of their models,
while the recent interest in quasi-direct drive solutions is also favouring planetary solutions,
both in research and in commercial products like Genesis’ Reflex gearbox or the robotic drives
proposed among others by T-Motor, Dyna-Drive, Maxon, Spinbotics, Dephy, or the MIT’s
actuator. In fact, the recent incorporation of Melior Motion’s PSC gearbox in Kuka’s KR Iontec
robot and the acquisition of the former by the Schaeffler group could also be an indication that
manufacturers of traditional industrial robots are also starting to look at planetary alternatives
for their future robotic joints.

ADVANTAGES OF PLANETARY GEARBOX
Planetary gears are frequently used when space and weight are an issue, but a large amount of
speed reduction and torque are needed. This requirement applies to a variety of industries,
including tractors and construction equipment where a large quantity of torque is wanted to
drive the wheels. There are several reasons to use planetary gearboxes in various applications.
Here are some key advantages:
⇒Compact-Design:
Planetary gearboxes are known for their compact and space-saving design. The
arrangement of gears in a planetary system allows for high torque transmission in a
smaller physical space compared to other gearbox configurations.
⇒High Torque Density: Planetary gearboxes provide high torque output relative to
their size. This makes them suitable for applications where a high torque is required in
a limited space.
⇒Efficiency: Planetary gear systems often exhibit high efficiency due to multiple gear
engagements, resulting in better power transmission. This efficiency is crucial in many
applications, such as automotive and industrial machinery.
⇒Versatility: Planetary gearboxes offer versatility in terms of speed reduction or
increase, as well as torque multiplication or reduction. This makes them suitable for a
wide range of applications, from robotics and automation to wind turbines and
aerospace.
⇒Precision and Accuracy: Planetary gears are known for their precision and accuracy
in maintaining gear meshing. This makes them suitable for applications where precise
control of speed and position is critical, such as in robotics and CNC machinery.
⇒Shock Load Resistance: The multiple gear contacts in a planetary system help
distribute the load, making these gearboxes more resistant to shock loads. This feature
is advantageous in applications where sudden changes in load or impact can occur.
⇒Low Backlash: Planetary gear systems can be designed with low backlash, providing
better positional accuracy. This is particularly important in applications like robotics
and automation where precise movement control is essential.
⇒High Ratios in a Single Stage: Planetary gearboxes can achieve high gear ratios in a
single stage, reducing the need for multiple stages of gearing. This simplifies the design
and can lead to a more efficient and reliable system.
⇒Quiet Operation: The design of planetary gear systems can result in quieter operation
compared to some other types of gearboxes. This is advantageous in applications where
noise reduction is a priority.
⇒Reliability and Durability: Planetary gearboxes are known for their reliability and
durability. The distributed load-carrying capability and robust construction make them
suitable for demanding industrial applications.

LIMITATIONS OF PLANETARY GEARBOX
⇒ Cost of planetary gear system will be high as compared to traditional gearbox.
⇒ Planetary gear system designing and manufacturing are quite complex.
⇒ Determination of efficiency of planetary gear system will be difficult.
⇒ Gearing should be accurate.
⇒ Some planetary gearing arrangement makes additional sound during operation.
⇒ To avoid any additional gearing, driving member and driven member must be
concentric.
APPLICATIONS OF PLANETARY GEARBOX
Planetary gearboxes, also known as epicyclic gearboxes, are widely used across various
industries due to their compact size and ability to transmit high torque. Here are some of the
key applications:
• Automotive: They are commonly found in automatic transmissions, providing a
range of gear ratios and smooth power transmission.
• Aerospace: Used in aircraft engines and control systems for their reliability and high-
power density.
• Robotics: Planetary gearboxes improve torque and precision in robotic arms and
drive systems.
• Industrial Machinery: Employed in heavy machinery for precise speed control and
to handle high torque loads, such as in conveyor systems, winches, and hoists.
• Electric Vehicles: Due to their efficiency, they are increasingly used in the
drivetrains of electric cars and other EVs.
• Printing Presses: They reduce the speed of rollers in printing presses for consistent
and quality prints.
• Packaging Machines: In packaging industries, they ensure reproducible products by
providing precise motion control.
• Bicycles: Some bicycle gear systems use planetary gearing for their shifting
mechanisms.
These gearboxes are favoured for applications that require properties such as high torque
density, operational efficiency, and durability. Their design allows for multiple gear ratios to
be obtained from a small volume, making them ideal for space-constrained applications.

Analysis And Solutions For Planetary Gearbox Gear Damage
The planetary gear reducer is a highly utilized device in the transmission system. In industrial
and mechanical applications, the presence of planetary gear reducers is quite common. For a
device with such high efficiency, issues of gear damage are inevitable. Generally, gear damage
can be categorized into three types: tooth breakage, gear pitting and spalling, and gear wear.
So, what are the underlying causes behind these three types of damage? And how can we
address them?
⇒ Tooth Breakage:
In general, tooth breakage in planetary gear reducers can be classified into fatigue fracture
and overload fracture. During operation, the gear teeth of a planetary gear reducer are
subjected to alternating loads, resulting in bending fatigue stress on the critical tooth profile.
This leads to the initiation of fatigue cracks at the tooth root. Under the influence of
alternating bending fatigue stress, these cracks gradually propagate, ultimately causing
fatigue fracture of the gear teeth.
Additionally, in the operational scenario of a planetary gear reducer, gears can experience
short-term overloads, impact loads, or severe wear and thinning of tooth profiles. Any of
these conditions can result in overload fracture.
Solution: Increasing the root fillet radius and minimizing the surface roughness values during
machining can reduce the impact of stress concentration. This, in turn, enhances the stiffness
of the shaft and bearings, alleviating localized loading on the tooth surfaces. Providing
sufficient toughness to the core of the gear teeth is essential. Additionally, implementing
appropriate strengthening treatments at the tooth roots can improve the gear teeth’s resistance
to fracture. Certainly, if gear breakage has already occurred during operation, it is necessary
to replace the damaged parts with new ones of the same model.
⇒ Gear Pitting and Spalling
In the prolonged operation of a planetary gear reducer, surface pitting and spalling may occur
on the gear teeth. This is primarily due to insufficient contact fatigue strength of the gears.
Unlike wear, where metal is worn away in particle form, pitting and spalling involve the
detachment of metal in chunks, causing depressions on the tooth surface and severely
compromising the accuracy of the tooth profile.
The process of this damage unfolds as follows: tiny cracks first appear on the tooth surface,
with lubricating oil entering these fatigue cracks. Through repeated engagement and
disengagement, the cracks progressively extend and propagate. The lubricating oil fills the
cracks as they expand, until a small piece of metal detaches, leaving the tooth surface. This
phenomenon disrupts the normal meshing performance of the gears.
The main causes of surface pitting on the gear teeth are:
(1) Material, Hardness, and Defects: The material of the gears does not meet the requirements.
A major factor affecting the contact fatigue strength of the gears is the lower hardness after

heat treatment, which fails to ensure the necessary contact fatigue strength. Additionally,
surface or internal defects on the gears contribute to insufficient contact fatigue strength.
(2) Poor Gear Accuracy: Inadequate gear processing and assembly precision, such as poor
meshing accuracy and motion precision. Discrepancies in the center distance of the housing for
helical gears can also contribute to this issue.
(3) Inappropriate Lubricating Oil: The lubricating oil used does not meet the requirements.
Incorrect oil grade, low viscosity, and poor lubricating performance are factors contributing to
this problem.
(4) Excessive Oil Level: An elevated oil level leads to higher oil temperatures, reducing the
viscosity of the lubricating oil, impairing lubrication performance, and diminishing the
working thickness of the oil film.
Solution: To address surface pitting, it is recommended to increase the hardness of the gear
teeth, minimize the surface roughness values, utilize a larger modification factor whenever
possible, increase the viscosity of the lubricating oil, and reduce dynamic loads. These
measures can help prevent fatigue pitting on the gear teeth.
⇒ Gear Wear
Mechanical components are susceptible to varying degrees of wear during prolonged use, and
planetary gear reducers are no exception.
Gear wear is the most common form of damage in the operation of planetary gear reducers.
Possible causes of this wear include: insufficient lubrication, the presence of metal particles in
the lubricating oil from wear, leading to surface wear on the gears; Gears with materials that
do not meet the requirements resulting in abnormal wear; presence of defects such as sand
holes, pores, looseness, insufficient modularization, etc.; inadequate or lack of heat treatment
hardness;
Inaccuracies in gear meshing and motion precision; high sensitivity of helical gears to center
distance errors, especially positive errors in center distance, not only reducing the bending
strength of the gear teeth but also increasing sliding wear.
Solution: To address gear wear in planetary gear reducers, it is recommended to:
1. Increase the surface hardness of the gears.
2. Reduce surface roughness values.
3. Keep the transmission components and lubricating oil clean.
4. Ensure thorough lubrication and add appropriate anti-wear additives to the lubricating
oil.
5. Introduce several magnetic bodies into the oil tank to utilize magnetic forces in
adsorbing metal particles in the lubricating fluid, reducing the metal particle content.
In planetary gear reducers, gears are among the core components, and the key to successful
planetary gear design lies in the uniformity and high precision of gear meshing.
Regardless of the extent of gear damage, prompt repair or replacement of the gears is essential
to prevent severe impacts on mechanical transmission.

CANVASES
AEIOU CANVAS
The AEIOU canvas is a tool used in design engineering, specifically during ethnographic
research. Ethnography is a research method where researchers observe and analyze people's
behavior in their natural environment.
The AEIOU framework helps researchers code their observations and identify patterns.
AEIOU stands for the following:
• Activity: This refers to the specific actions people take to achieve a goal.
• Environment: This is the physical and social setting where the activity takes place.
• Interaction: This describes how people interact with each other and with objects in the
environment.
• Object: These are the tools and things people use during the activity.
• User: This refers to the people whose behavior is being observed.
By analyzing these five elements, researchers can gain a deeper understanding of how people
use products and services. This information can then be used to improve the design of those
products and services.

MIND MAP CANVAS
A Mind Map canvas isn't a specific term, but it refers to the digital space where you create
mind maps. Unlike a physical piece of paper, a digital mind map canvas offers several
advantages:
• Unlimited space: You can brainstorm and add as many ideas as you want without
worrying about running out of room.
• Flexibility: You can easily move, rearrange, and connect ideas without having to erase
and redraw anything.
• Collaboration: Some mind mapping tools allow you to work on the same mind map
with others in real-time.
• Visual appeal: You can add colors, shapes, images, and icons to make your mind map
more visually engaging and memorable.
Here are some additional things to keep in mind about Mind Map canvases:
• Templates: Many mind-mapping tools offer pre-made templates for different purposes,
such as brainstorming, taking notes, or project planning.
• Exporting: You can usually export your mind map as an image file, PDF, or text
document to share with others or use it in other applications.
If you're looking for a way to brainstorm ideas, organize your thoughts, or visually
represent information, a mind map canvas can be a valuable tool.

IDEATION CANVAS
An Ideation Canvas is a tool used to brainstorm and develop new ideas, particularly
during the initial stages of a design thinking process. It provides a structured framework
to explore various possibilities and encourage creative problem-solving.
There isn't a single standardized Ideation Canvas, but different variations exist. Here's
a breakdown of the general concept:
Structure:
The canvas typically consists of several sections that prompt you to consider different
aspects of your idea. The specific sections may vary depending on the canvas version,
but some common elements include:
• Problem: Clearly define the problem you're trying to solve.
• Target Audience: Identify the specific group of people you're designing for.
• Value Proposition: Describe the unique benefit your idea offers to the target audience.
• Solution Brainstorming: This section is where you generate a wide range of potential
solutions to the problem. Techniques like brain storming or SCAMPER (Substitute,
Combine, Adapt, Modify, Put to Other Uses, Eliminate, Rearrange) can be used here.
• Feasibility Check: Evaluate the practicality and viability of your ideas. Consider factors
like resources, technology, and market fit.
• Next Steps: Define what actions need to be taken to further develop your most
promising ideas.
It encourages you to think outside the box and come up with a variety of solutions.

PRODUCT DEVELOPMENT CANVAS
A product development canvas is a strategic business tool that helps visualize and
organize key aspects of your product. It's a one-page framework that allows you to see
the big picture and ensure all crucial elements are considered during the development
process.
Here's a breakdown of the product development canvas:
Purpose:
• Streamline product development by bringing all the essential information together.
• Foster clear communication and understanding within the product team.
• Identify potential gaps or weaknesses in the product concept.
• Validate the product's value proposition and ensure it aligns with user needs.
Using a product development canvas offers several advantages:
• Improved Focus: It keeps your product development process focused on user needs and
market fit.
• Early Identification of Issues: By visualizing the entire product concept, you can
identify potential problems early on and course-correct if necessary.
• Enhanced Collaboration: It serves as a shared document that promotes communication
and understanding among team members.
• Increased Efficiency: Streamlines the development process by ensuring everyone is
on the same page.

LNM CANVAS
The Learning Needs Matrix Canvas is a tool used to identify and prioritize training
needs within a team or organization. It provides a structured approach for analyzing the
skills and knowledge gaps of your workforce and developing targeted
learning solutions.
Benefits:
• Needs Identification: The canvas helps you systematically identify the specific skills
and knowledge gaps within your workforce.
• Prioritization: It allows you to prioritize learning needs based on their criticality for
different roles and the overall goals of the organization.
• Targeted Learning: By clearly identifying the gaps, you can develop more targeted and
relevant training programs that address specific needs.
• Resource Allocation: It helps with efficient resource allocation by focusing training
efforts on the areas with the highest impact.

PROTOTYPE
DESIGN OF SPUR GEAR
We have taken given dimensions in 3D model of SPUR GEAR,
Diameter of Addendum Circle: 76mm & Addendum: 2mm
Diameter of Circular Pitch: 72mm & Circular Pitch: 6.3mm
Diameter of Dedendum Circle: 67mm & Dedendum: 2.45mm
Face width: 16mm & Face radius: 8.875mm
Tooth Thickness: 3.14mm & Number of Teeth: 36
Front view Side & Top view

Modeling View Visualization
This 3D design or model of Spur gear is created in 3D modeling software Shapr3D,with taking
above dimensions.
Spur gear Design Link: https://collaborate.shapr3d.com/v/Dj2_s0ePOOl-c8GQNWDFj
QR code for Spur Gear Design:

DESIGN OF BEVEL GEAR
We have taken given dimensions in 3D model of SPUR GEAR,
Back cone: 69° & Back cone Distance: 32mm
Pitch angle: 55.5° & Pitch Diameter: 48mm
Root angle: 52.5° & Outside Diameter: 54mm
Face angle: 58.5° & Face Width: 7mm
Addendum angle = Dedendum angle: 3°
Number of teeth on main Bevel gear: 30
Number of teeth on Pinon: 20
Front View Right Side View

Top View Modeling View
Visualization
This 3D design or model of Bevel gear is created in 3D modeling software Shapr3D,with taking
above dimensions.
Bevel gear Design Link: https://collaborate.shapr3d.com/v/Cwbm9XLBY9yFl9TZu_5Ux
QR code for Bevel Gear Design:

DESIGN OF PLANETARY GEARBOX
→ Design and Calculations of Planet Gear and Sun Gear:
→ Design and Calculations of Ring Gear compare to Planet Gear:

Front View Back View
Default View
This 3D design or model of Bevel gear is created in Autodesk Inventor Professional 2024,with
taking above dimensions. We have given the motion to the Gearbox.

DETAILS ABOUT MODEL
• Design of Spur Gear and Bevel Gear:
We have created a 3D model or design of Spur Gear and Bevel Gear in 3D
modeling software Shapr3D. It can be download from Microsoft store.
The detail about how we designed the gears is given in the PROTOTYPE
section.
• Design of Planetary Gearbox:
We have created a design of Planetary Gearbox in Autodesk’s software,
Inventor Professional 2024.
In the design of Planetary gearbox,
At first we have designed Planetary gears and Sun gear where Planetary gears
have 24 teeth and Sun gear has 48 teeth.
After we designed Ring Gear with compare to Planetary gears, where Ring
gear has 96 teeth.
Then we designed carrier to attach the all types of gears, it means 4 planetary
gears, a Sun gear and a Ring gear.
After the modeling of Planetary gear box, we defined constraints and gave the
motion to the gearbox.
Designed all Types of Gears

Design of carrier
Attachment of all gears on carrier

Give the constraints and motion

FUTURE DEVELOPMENT OF PLANETARY GEARBOX
The future development of planetary gearboxes is quite promising, with several advancements
on the horizon. Here are some key points:
• High-Ratio Planetary Gearboxes: There’s potential for high-ratio planetary gearboxes
in next-generation robotics. These gearboxes are being considered for their versatility
and ability to provide high torque density, which is essential for applications like
helicopters, cars, submarines, wind turbines, and industrial robots.
• Collaborative Robotics (Cobots): Modern collaborative robotic devices, which require
lightweight actuation, are increasingly favoring the use of planetary gearboxes.
Manufacturers like Kinova and Automata are incorporating self-developed planetary
gearboxes in some of their models.
• Quasi-Direct Drive Solutions: The interest in quasi-direct drive solutions is also
favoring planetary gearboxes, both in research and commercial products. This includes
gearboxes like Genesis’ Reflex gearbox and robotic drives by companies such as T-
Motor, Dyna-Drive, Maxon, Spinbotics, Dephy, and MIT’s actuator.
• Market Growth: The global industrial planetary gearbox market is expected to see
significant expansion, with an anticipated valuation of US$ 6.5 billion by 2033. This
growth is driven by a steady Compound Annual Growth Rate (CAGR) of 5.2% from
2023 to 2033, with increasing demand for precision gearboxes, especially within
the cement industry.
These developments indicate a resurgence in the use of planetary gearboxes, particularly in
robotics and precision applications, where their compact size and high efficiency
are highly valued.

CONCLUSION
In conclusion, the project on 3D design and modeling of a Planetary Gearbox has demonstrated
the intricate process of creating a highly efficient and compact gear system. The design process
involved understanding the mechanics of planetary gears, selecting appropriate gear ratios, and
utilizing CAD software for precise modeling. The 3D printing of the gearbox components
allowed for a tangible examination of the gear set’s functionality and performance.
The project highlighted the versatility of planetary gearboxes, which are capable of providing
high torque and efficiency in a small form factor. This makes them ideal for various
applications, from industrial machinery to robotics and automotive transmissions. The hands-
on experience of assembling and testing the gearbox provided valuable insights into the
practical aspects of mechanical design and the potential for customization in gear systems.
Overall, the project not only showcased the technical skills involved in 3D modeling and
printing but also emphasized the importance of iterative design and testing in the development
of mechanical components. The successful design and modeling of the Planetary Gearbox serve
as a testament to the capabilities of modern engineering tools and the potential for innovation
in mechanical design.
REFERENCES
1. Spur gear - Wikipedia
2. Bevel gear - Wikipedia
3. Epicyclic gearing - Wikipedia
4. What is a Planetary Gear? (regalrexnord.com)
5. On the Potential of High-Ratio Planetary Gearboxes for Next-Generation Robotics | Power
Transmission Engineering Magazine
6. In what applications are planetary gearboxes commonly used, and why? (kavitsu.com)
7. (4) Analysis and Solutions for Planetary Gearbox Gear Damage | LinkedIn

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